Stay-in-Place Forms and Methods and Equipment for Installation Thereof

ABSTRACT

Stay-in-place forms and methods and equipment for installing thereof. A concrete form includes a vertical component and a horizontal component, the vertical component located substantially perpendicular to the horizontal component. Also, the form includes an interior surface, at least a portion of the interior surface providing a form for supporting uncured concrete; wherein the uncured concrete forms a concrete structural portion upon curing of the uncured concrete; and wherein the interior surface remains attached to the concrete structural portion after curing. The form may include inserts and compatible form attachments. Also, forms including recesses may be utilized to reduce the weight thereof. Lifting equipment and accessories may be utilized to lift the form from a form holder and set same in place. Forms contain the work area as soon as it is installed to minimize fall hazards and the time, costs, and downtime associated with installation of safety measures.

BACKGROUND OF THE INVENTION

Embodiments of the present invention generally relate to stay-in-placefascia forms and methods and equipment for installation thereof.Conventional construction methods for building bridges are knownincluding those which use bridge brackets, scaffolding, and many othertypes of form support to support the loads from wet concrete. Fasciaformwork is typically made from wood or steel and requires removal afterthe bridge is constructed. Known apparatus and methods involvesubstantial issues of safety and maintenance and protection of traffic(“MPT”). Known apparatus and methods also incur substantial labor cost,material cost, and costs associated with handling and disposal of suchmaterials.

A common method of bridge building includes the use of bridge bracketsinstalled along the fascia of the bridge and at or near the bottom ofthe bridge deck. Such brackets are typically installed with wooden formsthat require removal after concrete placement. This method is laborintensive and results in high material costs. Moreover, disposal costs,MPT costs (if applicable), and safety costs are incurred.

Concrete paving machines are also known for bridge construction. Suchmachines use truss units to carry the machine and associated parts. Theyalso use bogie wheel, rails, and screw jack adjustors to facilitate thepaving process.

SUMMARY OF THE INVENTION

Briefly stated, in one aspect of the present invention, a concrete formis disclosed. This concrete form includes a vertical component and ahorizontal component, the vertical component located substantiallyperpendicular to the horizontal component. Also, the form includes aninterior surface, at least a portion of the interior surface providing aform for supporting uncured concrete; wherein the uncured concrete formsa concrete structural portion upon curing of the uncured concrete; andwherein the interior surface remains attached to the concrete structuralportion after formation.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofpreferred embodiments of the invention, will be better understood whenread in conjunction with the appended drawings. For the purpose ofillustrating the invention, there is shown in the drawings embodimentswhich are presently preferred. It should be understood, however, thatthe invention is not limited to the precise arrangements andinstrumentalities shown. In the drawings:

FIGS. 1A and 1B depict perspective and plan views of a stay-in-placefascia form in accordance with one embodiment of the present invention;

FIG. 2 depicts a side view of the fascia form of FIGS. 1A and 1Bpositioned atop the outer edge of a structural member in accordance withone embodiment of the present invention;

FIGS. 3A through 3I depict progressive side, perspective, and sectionviews of a structure created via one process for creating a concretestructure utilizing the fascia form shown in FIGS. 1A, 1B, and 2 inaccordance with one embodiment of the present invention;

FIG. 4A depicts a perspective view of a form holder in accordance withone embodiment of the present invention;

FIG. 4B depicts erection equipment for installing a plurality of formsstacked atop the form holder of FIG. 4A in accordance with oneembodiment of the present invention;

FIG. 5 depicts a perspective view of a stay-in-place fascia form havinga plurality of recesses in accordance with one alternate embodiment ofthe present invention;

FIG. 6 depicts an elevational view of a stay-in-place fascia form havinga plurality of recesses in accordance with the alternate embodiment ofthe present invention depicted in FIG. 5;

FIG. 7 depicts a side view of a stay-in-place fascia form having aplurality of recesses in accordance with the alternate embodiment of thepresent invention depicted in FIGS. 5 and 6;

FIG. 8A depicts a perspective view of a stay-in-place fascia form havinga plurality of apertures and a recess in accordance with one alternateembodiment of the present invention;

FIG. 8B depicts an elevational view of a stay-in-place fascia formhaving a plurality of apertures and a recess in accordance with thealternate embodiment of the present invention depicted in FIG. 8A;

FIG. 8C depicts a side view of a stay-in-place fascia form having aplurality of apertures and a recess in accordance with the alternateembodiment of the present invention depicted in FIGS. 8A and 8B;

FIG. 9A depicts a perspective view of a stay-in-place fascia form havinga plurality of vertical recesses and a horizontal recess in accordancewith one alternate embodiment of the present invention;

FIG. 9B depicts a plan view of a stay-in-place fascia form having aplurality of vertical recesses and a horizontal recess in accordancewith the alternate embodiment of the present invention depicted in FIG.9A;

FIG. 9C depicts a side view of a stay-in-place fascia form having aplurality of vertical recesses and a horizontal recess in accordancewith the alternate embodiment of the present invention depicted in FIGS.9A and 9B;

FIG. 9D depicts a cross-sectional view of the vertical recess depictedin FIGS. 9A through 9C as taken along lines 9D-9D of FIG. 9A;

FIG. 10A depicts a perspective view of a form in accordance with oneembodiment of the present invention;

FIG. 10B depicts a side view of a primary support in use with the formof FIG. 10A in accordance with one embodiment of the present invention;

FIG. 10C depicts a side view of the form of FIG. 10A positioned atop theouter edge of a structural member in accordance with one embodiment ofthe present invention;

FIG. 10D depicts an enlarged side view of the intersection of thehorizontal and vertical components of the form of FIG. 10A in accordancewith one embodiment of the present invention;

FIG. 10E depicts an enlarged side view of the distal end of thehorizontal component of the form of FIG. 10A in accordance with oneembodiment of the present invention;

FIG. 10F depicts a side view of a secondary support for use with theform of FIG. 10A in accordance with one embodiment of the presentinvention;

FIG. 10G depicts a top view of a secondary support for use with the formof FIG. 10A in accordance with one embodiment of the present invention;

FIG. 10H depicts a top view of an interior reinforcement for use withthe form of FIG. 10A in accordance with one embodiment of the presentinvention;

FIG. 10I depicts a top view of the upper plate of the primary support ofFIG. 10B;

FIG. 10J depicts an enlarged side view of the distal end of thehorizontal component of the form of FIG. 10A having an alternate distalend and upwardly facing surface in accordance with one embodiment of thepresent invention;

FIG. 10K depicts an enlarged side view of the distal end of thehorizontal component of the form of FIG. 10A having an alternate distalend that includes a thickened distal end in accordance with oneembodiment of the present invention;

FIG. 11A depicts a perspective view of an alternate form mounted atop aconcrete structural member in accordance with one embodiment of thepresent invention;

FIG. 11B depicts a side view of the alternate form of FIG. 11A inaccordance with one embodiment of the present invention;

FIG. 11C depicts an enlarged side view of the intersection of thehorizontal and vertical components of the form of FIG. 11A in accordancewith one embodiment of the present invention;

FIG. 11D depicts a plan view of the alternate form of FIG. 11A inaccordance with one embodiment of the present invention;

FIG. 11E depicts a side view of the alternate form of FIG. 11A mountedatop a concrete structural member in accordance with one embodiment ofthe present invention;

FIG. 11F depicts a side view of a secondary support for use with theform of FIG. 11A in accordance with one embodiment of the presentinvention;

FIG. 12A depicts a perspective view of an alternate form atop astructural member in accordance with one embodiment of the presentinvention;

FIG. 12B depicts a side view of the alternate form of FIG. 12A mountedatop a structural member in accordance with one embodiment of thepresent invention;

FIG. 12C depicts an enlarged side view of the intersection of thehorizontal and vertical components of the form of FIG. 11A in accordancewith one embodiment of the present invention;

FIG. 13A depicts a perspective view of an alternate form atop astructural member in accordance with one embodiment of the presentinvention;

FIG. 13B depicts a side view of the alternate form of FIG. 13A mountedatop a structural member in accordance with one embodiment of thepresent invention; and

FIG. 13C depicts a side view of a primary support for use with formsincluding, but not limited to, the form of FIG. 13A in accordance withone embodiment of the present invention;

FIG. 13D depicts a side view of an alternate primary support for usewith forms including, but not limited to, the form of FIG. 13A inaccordance with one embodiment of the present invention;

FIG. 13E depicts a side view of another alternate primary support foruse with forms including, but not limited to, the form of FIG. 13A inaccordance with one embodiment of the present invention; and

FIG. 13F depicts a side view of an alternate primary support for usewith forms including, but not limited to, the form of FIG. 13A inaccordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology may be used in the following description forconvenience only and is not limiting. The words “lower” and “upper” and“top” and “bottom” designate directions in the drawings to whichreference is made. The terminology includes the words above specificallymentioned, derivatives thereof and words of similar import.

Where a term is provided in the singular, the inventors also contemplateaspects of the invention described by the plural of that term. As usedin this specification and in the appended claims, the singular forms“a”, “an” and “the” include plural references unless the context clearlydictates otherwise, e.g., “a form” may include a plurality of forms.Thus, for example, a reference to “a method” includes one or moremethods, and/or steps of the type described herein and/or which willbecome apparent to those persons skilled in the art upon reading thisdisclosure.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, the preferred methods,constructs and materials are now described. All publications mentionedherein are incorporated herein by reference in their entirety. Wherethere are discrepancies in terms and definitions used in references thatare incorporated by reference, the terms used in this application shallhave the definitions given herein.

Referring now to FIGS. 1A and 1B, depicted is an exemplary stay-in-placefascia form 100 in accordance with one embodiment of the presentinvention. This exemplary form 100 is utilized as a form for supportinguncured concrete, and, after the concrete has cured, form 100 remains anintegral part of the structure formed thereby. This exemplary form 100is intended for use in the construction of new bridges, specifically,bridge barriers such as traffic barriers. Although the described use ofform 100 is new bridge construction and barriers for same, the systemsand methods of the present invention are not limited to use for buildingbridges. They may be incorporated for the construction of otherstructures or other uses including, without limitation, bridge repairand/or rehabilitation, parapet construction, building construction, andthe like.

When used for bridge building, form 100 contains the work area as soonas it is installed as discussed in greater detail below, which minimizesor eliminates fall hazards, thereby eliminating the time, costs (e.g.,labor costs, removal costs, disposal costs, etc.), and downtimeassociated with installation of safety measures that are typicallyrequired (e.g., formwork, scaffolding, road closure, etc.) to containthe work area. That is, minimal or zero excess materials are needed tocontain the work area since the form performs this task while alsoremaining in place after construction to become part of the structurebeing built. Also, the disruption of traffic or other environmentalconsiderations beneath the structure being built is minimized as allwork can be safely performed from atop the structure.

Now referring to FIGS. 1A, 1B, and 2, form 100 is a relatively thin,substantially L-shaped panel that includes vertical component 102 andhorizontal component 104. In the depicted embodiment, vertical component102 is located substantially perpendicular to horizontal component 104,however, alternate orientations may be substituted.

Vertical and horizontal components 102 and 104, respectively, havethicknesses T₁ of approximately two inches (2″), however, alternatethicknesses may be substituted without departing from the scope of thepresent invention. Also, embodiments are envisioned in which thethicknesses of the vertical and horizontal components are not equal.

The height H₁ of form 100 is approximately forty four inches (44″), thewidth W₁ is approximately two feet (2′), and the length L₁ isapproximately sixty inches (60″), however, varied dimensions may besubstituted to accommodate, for example, desired size of the structurebeing built as well as material strength and geometric boundaries. Forexample, alternate embodiments are envisioned in which width W₁ isapproximately twelve inches (12″), but the invention is not so limited.

As best seen in FIG. 2, in the depicted embodiment of the presentinvention, upwardly facing surface 222 of vertical component 102inclines upwardly and inwardly toward interior surface 106 at an angleof approximately thirty degrees (30°), however, varying angles may besubstituted.

Form 100 has an interior surface 106 that includes upwardly facingsurface 108 of horizontal component 104, inwardly facing surface 110 ofvertical component 102, and inwardly facing surface 234 of joiningcomponent 210. In the exemplary embodiment of the present inventionshown in FIG. 2, joining component 210 extends at an angle of 45 degrees(45°) relative to said inwardly facing surface 110 of said verticalcomponent and said upwardly facing surface 108 of said horizontalcomponent. However, alternate configurations may be substituted withoutdeparting from the scope hereof.

Interior surface 106 provides a form for supporting uncured concrete asdiscussed in greater detail below. Once the concrete has cured, form 100remains in place and forms a structural portion of the bridge beingbuilt or remains in place as a permanent part that does not havestructural significance. That is, interior surface 106 remains attachedto the cured concrete after curing/formation of same. In this case,exterior surface 112 becomes an exterior surface of the bridge. In someembodiments such as the one depicted in FIG. 2, exterior surface 112includes one or more ornamental features 240 or other aesthetics toprovide a decorative exterior or surface for the structure. Exteriorsurface 112 may include the downwardly facing surface 114 (e.g., asoffit) of horizontal component 104, the outwardly facing surface 116 ofvertical component 102, bevel 212, and/or any portion or combinations ofthe aforementioned items.

In some embodiments of the present invention such as that shown in FIG.2, the upper corner of a distal end of horizontal component 104 is inthe form of rounded edge 214. However, alternate configurations and/orshapes for this edge may be substituted including, without limitation asquared edge, a chamfered edge or edge treatment. Or edge 214 may beomitted, without departing from the scope hereof.

Additionally, in some embodiments of the present invention such as thatshown in FIG. 2, bevel 212 extends longitudinally along the intersectionof outwardly facing surface 116 of vertical component 102 and downwardlyfacing surface 114 of horizontal component 104. Bevel 212 acts as a dripedge to cause water to drip downward rather than along downwardly facingsurface 114. Bevel 212 is located at an angle of forty-five degrees(45°) relative to outwardly facing surface 116 of vertical component 102and downwardly facing surface 114 of horizontal component 104. However,alternate configurations and/or shapes for this bevel may besubstituted, or bevel 212 may be omitted, without departing from thescope hereof.

Additionally, in some embodiments of the present invention such as thatshown in FIG. 2, protrusion 216 extends below downwardly facing surface114 of horizontal component 104 directly below joining component 234.Protrusion 216 has a substantially semicircular cross-section, and itacts as a drip strip to cause water to drip downward rather than alongdownwardly facing surface 114. Protrusion 216 and bevel 212 both act toeliminate or minimize the amount of water that reaches structuralsupport 302 in an effort to minimize corrosion thereof. However,alternate configurations, locations, and/or shapes for this protrusionmay be substituted, or protrusion 216 may be omitted, without departingfrom the scope hereof including, without limitation, a longitudinalrecess.

Form 100 may be formed of many different types of materials orcombinations thereof, provided that the strength of the material, orcombination of materials, is sufficient to hold the implied loads suchas that of the uncured concrete. In the depicted embodiment, form 100 ismade from 5,000 PSI fiber-reinforced concrete, however, other materials,or combinations of materials, including, but not limited to, polymersand/or high strength concretes may be substituted.

Optionally, form 100 may include an interior reinforcement 242. In thedepicted embodiment, interior reinforcement 242 is a four-by-four(4″×4″) epoxy-coated, welded wire mesh that extends substantiallythroughout the height of vertical component 102 and the width ofhorizontal component 104 with the exception of a bend at theintersection thereof. The portion of the depicted interior reinforcement242 located within vertical component 102 is located approximatelyequidistant from inwardly facing surface 110 and outwardly facingsurface 116. The portion of the depicted interior reinforcement 242located within horizontal component 104 is located approximatelyequidistant from upwardly facing surface 108 and downwardly facingsurface 114. These two portions are connected to each other via a curvein the interior reinforcement, such curve having a radius ofapproximately four inches (4″). However, alternate locations andconfigurations may be substituted including, without limitation,reinforcements made of carbon mesh or other materials having tensilestrength and reinforcements having partially exposed portions (portionsthat extend beyond the confines of form 100). Or interior reinforcement242 may be omitted without departing from the scope hereof.

Form 100 may optionally include a rabbet such as rabbet 218 to assist inplacement of form 100 atop a structural member 302 (e.g., a girder,stringer, etc.) as discussed in greater detail below. In the depictedembodiment, rabbet 218 extends longitudinally along the distal lowercorner of horizontal component 104 and it is substantially L-shaped.That is, when form 100 is viewed in its upright position, rabbet 218 isin the form of an L that has been inverted and rotated 90 degreescounterclockwise. However, alternate shapes may be substituted withoutdeparting from the scope hereof. Further, although structural member 302is depicted in the shape of a traditional bridge girder, structuralmember may have virtually any shape or configuration and form 100 and/orrabbet 218 may be modified accordingly, as needed.

As best seen in FIG. 2, form 100 includes a plurality of inserts 202. Inthe depicted embodiment, inserts 202 are threaded, plastic inserts suchas the precast concrete plastic inserts manufactured by A.C. MillerConcrete Products, Inc. and having model no. IN-025 through IN-150.However, alternate inserts may be substituted including, but not limitedto, galvanized steel inserts and non-threaded inserts. Or, aperturespassing completely through horizontal and/or vertical components 102 and104, respectively, may be substituted. In the depicted embodiment,inserts 202 are embedded in form 100 during manufacturing thereof (e.g.,during the casting of the form via a concrete mold), however, alternateembodiments are envisioned in which such inserts are installed aftercasting and/or placement of form 100 as discussed in greater detailbelow. Additionally, although form 100 includes seven (7) inserts 202,varying quantities may be substituted. For example, in one alternateembodiment, a plurality of inserts are provided in the form of a grid toallow multiple exterior reinforcement style form attachments 206 to beinstalled (as discussed below) to increase the coupling between form 100and any adjacent cast-in-place concrete structures or structureportions.

In the depicted embodiment, inserts 202 are compatible with a variety ofform attachments 206. Form attachments 206 may perform any one of anumber of functions including, without limitation, assisting withinstallation of form 100, increasing the strength of the interfacebetween form 100 and the cured concrete, and the like. Form attachments206 may be any one of a plurality of commercially available connectiondevices. For example, in the depicted embodiment, form attachments 206 aand 206 b are one-half inch (½″) threaded shank eye bolts with ashoulder as manufactured by Chicago Hardware, and form attachments 206 cand 206 d are exterior reinforcements. In the depicted embodiment, thisexterior reinforcement is a reinforcement bar of Grade 60 (i.e., 60,000PSI) such as an imperial size #4, one half inch (½″) diameterreinforcement bar that includes threads on its proximal end (e.g., thesethreads may be added during manufacturing or during construction of thestructure) and a J-shaped hook on its distal end. However, alternateexterior reinforcements may be substituted without departing from thescope hereof. Form attachments 206 connect to form 100 by simplythreading of same into a compatible insert such as insert 202 asdiscussed above.

Form attachments 206 a and 206 b facilitate attachment of a tie or thelike during installation of form 100 and prior to the pouring ofconcrete as discussed in greater detail below. That is, the tie may bethreaded through the eye of form attachments 206 a and 206 b prior tothe tying thereof. In the depicted embodiment, form attachments 206 aare threaded into inserts 202 a, and form attachments 206 b are threadedinto inserts 202 c as depicted in FIG. 2.

Additionally, a form attachment 206 a or 206 b may be threaded intoinsert 202 d to facilitate coupling of form 100 to a lifting cable 310via a coupler 309 or the like prior to placement of same as discussedbelow. That is, coupler 309 or the like may be inserted through a formattachment 206 and/or a shackle coupled thereto to lift facilitate thelifting of form 100 from a stack of forms and/or from a form holder suchas form holder 404 as described below with respect to FIGS. 4A and 4B.In the depicted embodiment, such an attachment is threaded into insert202 d, which is located at the center of gravity of form 100. Thislocation minimizes movement of the form during lifting and placement,however, alternate locations may be substituted without departing fromthe scope hereof. After the form is set in place and detached fromlifting equipment 402, form attachment 206 a may be removed from insert202 d to allow the threading of a different form attachment theretoincluding, without limitation, form attachments 206 a, 206 b, 206 c,and/or 206 d as discussed above.

Form attachments 206 c and 206 d increase the bond between form 100 andthe concrete poured adjacent thereto. That is, after the concrete ispoured, exterior reinforcement-style form attachments 206 c and 206 dare encased therein and form a stronger, more permanent bond betweenform 100 and the poured concrete after curing of the latter. However,alternate form attachments 206, or varying quantities thereof, may beomitted or substituted without departing from the scope hereof. Forexample, form attachments 206 may include alternate hardware capable ofcoupling to, without limitation, S-hooks, shackles, coil rod ties, coilloop inserts, turnbuckles, washers and nuts, welded studs or hookedbrackets and the like, some or all of which is capable of purposesincluding, but not limited to, attaching to existing or proposed steel,wood, or concrete structural members and facilitating the attachment ofinboard formwork.

In one aspect of the depicted embodiment, interconnection clip 204 isoptionally mounted on upwardly facing surface 118 of the verticalcomponents 102 of adjacent forms 100. In the depicted embodiment, eachapproximate half of clip 204 is mounted atop upwardly facing surface 118of the vertical components of two adjacent forms 100 as best seen in theside view of FIG. 2. This coupling of two forms 100 via clip 204 allowsclip 204 to: distribute the load of each form 100 to its adjacent forms100, if any; maintain alignment of forms 100; and/or provide a mountingsurface for a railing or railing system.

As best seen in FIG. 2, this exemplary interconnection clip 204 includestop wall 224, inner wall 226, and outer wall 228. Top wall 224 mirrorsthe configuration of upwardly facing surface 222 of vertical component102. That is, top wall 224 inclines upwardly and inwardly toward innerwall 226 at an angle of approximately thirty degrees (30°). Inner andouter walls 226 and 228, respectively, extend downward from thelongitudinal edges of top wall 224 and extend throughout the full lengthof clip 204. The bottom edges of inner and outer walls 226 and 228,respectively, are located at the same height, thereby causing inner wall226 to be taller than outer wall 228 due to the angled nature of topwall 224. However, alternate configurations of clip 204 may besubstituted without departing from the scope hereof or clip 204 may beomitted entirely.

Interconnection clip 204 may optionally include railing support 220. Inthe depicted embodiment, railing support 220 includes a cylindricalportion 230 suspended above top wall 224 by vertical railing supportcomponent 232. Vertical railing support component 232 is approximatelythe same diameter as the railing to be threaded therethrough and has aninside diameter of approximately one and five-eighth inches (1⅝″), andis located along the approximate longitudinal centerline of top wall224. In the depicted embodiment, clip 204 only extends approximatelyone-tenth the length of form 100, however, other distances may besubstituted including, without limitation, a distance equal to the fulllength of form 100. Cylindrical portion 230 sits atop vertical railingsupport component 232 and is approximately centered thereupon. Itextends the full length of top wall 222. However, alternateconfigurations and/or locations may be substituted without departingfrom the scope hereof.

After installation of form 100, a railing (e.g., a cable, pipe, etc.)may be installed through railing support 220 to extend partially orthroughout the length of the bridge or other structure in accordancewith OSHA guidelines (to prevent or minimize falls during constructionof the structure) or for other purposes. That is, in one embodiment ofthe present invention, the height of form 100 is sufficient to eliminatethe need for a railing as per OSHA requirements. However, once the deck318 is poured, the height between the top of form 100 and deck 318 maybecome less than the minimum required by OSHA. In such a scenario, arailing may be added to meet OSHA requirements. However, alternateconfigurations of railing support 220 may be substituted withoutdeparting from the scope hereof or support 220 may be omitted entirely.Railing support 220 may also be eliminated without departing from thescope hereof. In one such embodiment, the height of form 100 isincreased to allow the panel to exceed the railing height required byOSHA, thereby eliminating the need for a railing.

Referring now to FIGS. 3A through 3I, depicted are progressive side,perspective, and section views of a structure created via one processfor installing form 100 on a structural member 302 in accordance withone embodiment of the present invention. In the depicted example,structural member 302 is a bridge fascia girder installed as known inthe art. Prior to placement of form 100 on structural member 302,structural member attachment 304 is—mounted on the structural member viawelding, J-hook bracket, or the like to facilitate the installation ofties that hold form 100 in place prior to the pouring of the concretedeck. In the depicted embodiment, structural member attachment 304 is awelded stud such as a High Strength, CPL Stud as manufactured by NelsonStud Welding and having part no. 101021688.

In the depicted exemplary form 100, structural member attachment 304 ismounted approximately one and one half inches (1½″) from the inner edgeof upwardly facing surface 306 of structural member 302, however,alternate locations may be substituted. Structural member attachments304 are located such that approximately two (2) structural memberattachments 304 are utilized for installation of each form 100 as bestseen in FIG. 3B, however, varying quantities may be substituted.

Also, alternate structural member attachments may be substituted withoutdeparting from the scope hereof. For example, structural memberattachments may be type B4L standoff support studs, type R9L rope hookstuds, Type R6P rectangular slotted studs, type SBL shoulder studs, typeTBL internally threaded studs, all as manufactured by Nelson StudWelding. Or, alternatively, structural member attachments may bedesigned to hook onto the side of structural member 302, therebyeliminating the need for welding thereof. One such structural memberattachment is the Century Series Hanger having model no. C130 asmanufactured by Dayton Superior.

In yet another alternate embodiment, a formwork attachment may besubstituted for, or used in addition to, the structural memberattachment. One such formwork attachment is a galvanized hook that hooksinto a slot that is cut into formwork such as formwork 312. Otherformwork attachments may include, but are not limited to, Hook Boltshaving model no. D1-J, D1LA, or D1L, coil loop straight inserts havingmodel no. B16, Inside Tie Rods having model nos. D1 and D18, and/or aheavy duty screed support having model no. G15, all as manufactured byDayton Superior.

After structural member attachments 304 are in place (as best seen inFIG. 3C), form 100 may be lifted via any capable lifting equipment(e.g., a crane, davit, etc.) such as that equipped with a lifting cable310 or the like for placement atop structural member 302. One suchmethod is described below with respect to FIG. 4B. Lifting cable 310 andan associated coupler 309 or the like may attach to form 100 via adirect or indirect attachment to form attachment 206 a. For example,intermediate coupling devices such as a shackle or the like may couplecoupler 309 to form attachment 206 a.

FIG. 3A depicts a side view of form 100 after it is lowered atopstructural member 302 such that rabbet 218 aligns with the upper andouter edge of structural member 302. For the purposes of FIG. 3A, 202 alocated to the right of 202 d (as best seen in FIG. 1B) has been removedto show one method of connecting lifting equipment 402 to insert 202 d.Form 100 is then rotated by lifting equipment 402 until verticalcomponent 102 is substantially plumb (i.e., substantially perpendicularto upwardly facing surface 306 of structural member 302) as best seen inthe side view of FIG. 3C.

Thereafter, form 100 is tied in place utilizing form attachments 206 a,206 b, structural member attachments 304, and one or more tie(s) 314 asdescribed below in order to secure form 100 to structural member 302.FIG. 3B depicts form 100 after it has been tied in place. It should benoted that, in the depicted embodiment, tie(s) 314 b are the primarysupport element (i.e., the primary mechanism utilized to hold the formin place prior to the pouring of the concrete) and tie(s) 314 a aresafety elements that prevent or minimize form 100 from beingaccidentally dislodged from structural support 302. Moreover, tie(s) 314a are installed in a substantially horizontal member as compared totie(s) 314 b, which are installed at an angle. End fittings for each ofthese ties may also be selected as needed. For example, tie(s) 314 a mayinclude adjusting nuts on one or more ends, whereas tie(s) 314 b mayinclude one or more turnbuckle-style end fittings. However, any endfitting may be substituted, or omitted, without departing from the scopeof the present invention.

Tie(s) 314 may be Inside Tie Rods as manufactured by Dayton Superior andhaving model no. D1 or D18. Tie rods may include various end fittings onone or both ends including, without limitation, turn buckle fittings.However, no such fittings are required to implement the presentinvention. Also, alternate structural member attachments and/or tiesincluding, without limitation, Richmond tie rod units may be substitutedwithout departing from the scope hereof.

Form 100 may be disconnected from lifting equipment 402 as soon as it issecured in place, and any form attachments required for connection ofform 100 to lifting equipment 402 may be removed, reused, or left inplace/unused. Any other desired form attachments including, withoutlimitation, exterior reinforcements or the like may be installed. Forexample, form attachments 206 c and/or 206 d may be installed in inserts202 b and/or 202 d to further increase the bond between the curedconcrete and form 100 as described in greater detail above. FIG. 3Cdepicts such exterior reinforcements after installation. Then, railing316 may be threaded through railing supports 220. FIGS. 3D, 3E, and 3Gdepict railing 316 after installation. It should be noted that formattachment(s) such as form attachments 206 c and 206 d may be installedat an alternate point in the process so long as they are installed priorto the pouring of deck 318. Also, railing 316 may be installed at anypoint in the installation process.

FIG. 3B depicts a perspective view of form 100 mounted and tied atopstructural member 302. FIGS. 3B and 3C also depict deck formwork 312,which is installed on the opposing side of structural member 302utilizing methods known in the art. Although it is anticipated thatformwork 312 is installed prior to placement of form 100 atop structuralmember 302, embodiments of the present invention are also envisioned inwhich form 100 is installed prior to formwork 312. It should also benoted that although formwork 312 is shown as an unfilled stay in placeform, filled stay in place forms are also compatible with the systemsand methods of the present invention. Such forms may be filled withfillers that include, but are not limited to, foam and concrete.

After form 100 is tied in place, it contains the work area as soon as itis installed as discussed in greater detail below, which minimizes oreliminates fall hazards, thereby eliminating the time, costs (e.g.,labor costs, removal costs, disposal costs, etc.), and downtimeassociated with installation of safety measures that are typicallyrequired (e.g., formwork, scaffolding, road closure, etc.) to containthe work area. That is, minimal or zero excess materials are needed tocontain the work area since the form performs this task while alsoremaining in place after construction to become part of the structurebeing built. Also, the disruption of traffic or other environmentalconsiderations beneath the structure being built is minimized as allwork can be safely performed from atop the structure.

FIG. 3D depicts a perspective view of form 100 mounted and tied atopstructural member 302 as well as deck formwork 312, deck rebar 320, andprimary barrier rebar 322 after it is installed on the opposing side ofstructural member 302, structural member 302, and upwardly facingsurface 108 of horizontal component 104. Deck rebar 320 and primarybarrier rebar 322 are installed as is also known in the art.

Referring now to FIG. 3E, depicted is a perspective view of form 100,structural member 302, and formwork 312 after the concrete has beenpoured to form deck 318. Deck 318 is formed upon the curing of theconcrete.

After the concrete is poured and cured, the portion of ties 314 bextending above deck 318 may optionally be removed from form attachments206 a as depicted in the side view of FIG. 3F. However, form attachments206 b and 206 c remain after curing of the concrete as they are encasedtherein.

The encasing of exterior reinforcement style form attachments 206 c inthe concrete deck 318 (and form attachment 206 d in barrier 326) furthercouples form 100 to concrete deck 318 and barrier 326, and facilitatesthe ability of form 100 to accommodate the shear and moment forcesplaced thereupon by the weight of the concrete deck 318. As discussedabove, the portion of tie(s) 314 b that extend above upwardly facingsurface 324 of concrete deck 318 may optionally be removed after curingof the deck concrete. Alternatively, it may be left in place and encasedin barrier 326 (See FIG. 3I). If a portion of tie(s) 314 b are removed,form attachments 206 a may also optionally be removed and/or replacedwith new form attachments including, but not limited to, exteriorreinforcement style form attachments such as form attachments 206 c and206 d to increase the coupling of form 100 to the barrier to be mountedadjacent thereto as discussed below. Or, as is shown in the depictedembodiment, form attachments 206 a are left in place and utilized toinstall substantially horizontal tie(s) 314 c (as best seen in FIG. 3H).Ties 314(c) couple form 100 to inboard formwork 334 (i.e., the formworkutilized to pour barrier 326) prior to the pouring of the concrete forbarrier 326 in an effort to further support the formwork and create agreater bond between form 100 and barrier 326 after curing of same.Tie(s) 314 c also assist with resisting the pressure applied to formwork334 and form 100 by the wet concrete poured to form barrier 326. Also,form attachments 206 a may also be replaced with a differing attachmentcapable of coupling ties 314 c to form 100 without departing from thescope hereof.

FIG. 3F depicts a side view of form 100, structural member 302, exteriorreinforcement 206 c, and formwork 312 after the concrete has been pouredto form deck 318 including dashed lines to indicate the componentsencased therein, namely, deck rebar 320, primary barrier rebar 322,lower form attachment 206 b, girder attachment 304, tie(s) 314 a, aportion of tie(s) 314 b, and exterior reinforcement 206 c. Asillustrated, primary barrier rebar 322 extends above upwardly facingsurface 324 thereof.

FIG. 3G depicts a perspective view of deck 318 after curing of theconcrete including structural member 302, formwork 312, primary barrierrebar 322, form 100, exterior reinforcement 206 d, and secondary barrierrebar 328. Secondary barrier rebar 328 is installed within and aboveprimary barrier rebar 322 as illustrated in FIG. 3G and as is known inthe art.

Finally, inboard barrier formwork 334 is put in place, ties 314 c areinstalled to secure formwork 334 to form 100, and the railing systeminstalled for safety purposes (i.e. clips 204 and railing 316) isremoved in preparation for the pouring of the barrier concrete. Therailing system may be removed before or after installation of theinboard barrier formwork 334. Ties 314 c are coupled to formworkattachment 336, which may be identical to, or similar to, formattachment 206 a, however, such attachment 336 is coupled to formwork334 either prior to, or after, such formwork is set in place. Then, theconcrete for barrier 326 is cast in place.

FIGS. 3H and 3I depict side and perspective views of form 100,structural member 302, tie(s) 314 c, deck 318, barrier 326, and formwork312 after the concrete has been poured to form barrier 326. FIG. 3H alsodepicts the components encased therein, namely, deck rebar 320, primarybarrier rebar 322, secondary barrier rebar 328, lower form attachment206 b, structural member attachment 304, tie(s) 314 a, a portion oftie(s) 314 b, tie(s) 314 c and exterior reinforcements 206 c and 206 d.The pouring of barrier 326 above upwardly facing surface 222 formsconstruction joint 330 between upwardly facing surface 222 and barrier326.

Now referring to FIG. 4, embodiments of the present invention alsogenerally relate to apparatus, systems, and methods for storing,transporting and/or installing fascia forms. Although the described useof such apparatus, systems, and methods is new bridge construction, theuse thereof is not limited thereto.

As depicted in FIG. 4, system 400 includes, inter alia, liftingequipment 402, form holder 404, and work bridge 406. System 400facilitates the erection/installation of a form such as, but not limitedto, form 100 as discussed above. Form holder 404 is designed to supporta plurality of forms in a stacked manner during storage, transportation,and installation. In the depicted embodiment, frame holder 404 is madeof steel but alternate materials may be substituted including, withoutlimitation, aluminum, other alloys, and combinations of the foregoingmaterials. Materials may be selected in order to minimize weight, butthis is not required to implement the systems and methods of the presentinvention.

As best seen in FIG. 4A, form holder 404 includes base section 408, rearsection 410, front section 412, rear intermediate section 414, and frontintermediate section 416, all of which are substantially rectangular. Inthe depicted embodiment, base section 408 and all of the aforementionedsections have lengths approximately equivalent to the forms to besupported by the form holder. However, varying lengths may besubstituted without departing from the scope hereof.

More specifically, form holder 404 includes a substantially rectangular,substantially horizontal base section 408. A substantially rectangularrear section 410 extends vertically from a first longitudinal side 418of base 408, and a substantially rectangular front section 412 extendsvertically from a second longitudinal side 420 of base 408. Asubstantially rectangular front intermediate section 416 extends at anangle of approximately forty five degrees from a first upperlongitudinal end 422 of said front section to base 408, and asubstantially rectangular rear intermediate section 414 extends at anangle of approximately forty five degrees from a second upperlongitudinal end 424 of said rear section to base 408. Rear intermediatesection 414 intersects front intermediate section 416 at an angle ofapproximately ninety degrees.

Additionally, in the depicted embodiment, rear intermediate section 414has a height approximately equal to a height of form 402 minus the widthof rear section 410. The height of front intermediate section 416 isthen selected to be the height that allows front intermediate section416 to be located substantially perpendicular to rear intermediatesection 414 without extending beyond front section 412. Similarly, theheight of front section 412 is selected to be equivalent to topmost edge426 of front intermediate section 416. However, varying dimensions maybe substituted without departing from the scope hereof.

In the depicted embodiment of the present invention, each of the basesection 408, rear section 410, front section 412, rear intermediatesection 414, and front intermediate section 416 are substantiallyrectangular and are not solid. Rather, these sections are comprised of aplurality of subframe support members 430 arranged to form substantiallyrectangular and/or square subframes 432 for each section. Many of thesesubframes 432 include angled support members 434 as depicted in FIG. 4A.Such support members are provided to increase the strength of thecorresponding section.

As also shown in FIG. 4A, a plurality of vertical section supports 436may be added to support rear intermediate section 414 and/or frontintermediate section 416 as necessary to increase the load bearingcapabilities of form holder 404.

The above described configuration of form holder 404 allows a pluralityof forms such as forms 100 to be stacked atop form holder 404 vialifting equipment such as lifting equipment 402 as described herein. Inthe depicted embodiment, spacers 428 are placed at predeterminedintervals between form holder 404 and the bottommost form, and alsobetween individual forms. In the depicted embodiment, spacers 428 arefurring strips having a width of approximately one inch (1″), however,alternate spacers may be substituted without departing from the scopehereof. Form holder 404 may also be used as a shipping pallet duringtransportation/shipping of one or more forms.

Also, embodiments of the present invention are envisioned in which oneor more layers of one or more sheets of plywood is placed atop theupwardly facing surface 440 of rear intermediate section 414 and/orfront intermediate section 416 to cover all or at least a portionthereof. Form 100 may be placed directly atop the plywood, or spacers428 may be incorporated between the plywood and form 100 withoutdeparting from the scope hereof.

Forms 100 are stacked in a position in which they are rotated backwardsat an angle of approximately forty five degrees. Form holder 404 of thedepicted embodiment is capable of supporting approximately nine thousand(9,000) pounds, however, alternate load capabilities may be substitutedwithout departing from the scope hereof.

As shown in FIG. 4, in the depicted embodiment, forms 100 and formholder 404 may be supported by workbridge 404 prior to installation. Forexample, workbridge 404 may be a Terex Bidwell thirty foot (30′) bythirty four (34′) foot heavy duty work bridge installed as in known inthe art. The workbridge is lightweight and works within the spacing ofthe screed rails that are typically installed by the contractor thatscreeds the finished concrete.

Forms and/or form holders with stacked forms may be located on one orboth ends of workbridge 404 while still allowing a sufficient spanbetween structural members to facilitate installation of forms asdescribed herein. However, other workbridges or equipment performing asimilar function may be substituted without departing from the scopehereof. The depicted embodiment of the present invention envisions amanually powered workbridge, however, workbridges having varying typesof control may be substituted including, without limitation, hydraulic,motor-driven, and mechanically driven lifting equipment. In scenarios inwhich a hydraulic drive is used on the workbridge, the same operatingengineer might control both the hydraulic drive system and hydraulicallycontrolled lifting equipment.

In the depicted embodiment, lifting equipment 402 is a crane. Forexample, lifting equipment may be a manually controlled davit crane asmanufactured by Dayton and having model no. 7CZ12. However, liftingequipment having varying types of control may be substituted including,without limitation, hydraulic, motor-driven, and mechanically drivenlifting equipment. In scenarios in which a hydraulic drive is used onthe workbridge, the same operating engineer might control both thehydraulic drive system and the hydraulically controlled davit.

Lifting equipment 402 may rest directly atop, for example, the screed orother equipment used for leveling the concrete. This equipmentincluding, without limitation, wheels and rails is installed as in knownin the art for the purpose of leveling the concrete. In some embodimentsof the present invention, a support 432 such as a beam or the like maybe utilized to further support and/or raise the height of liftingequipment 402.

In the depicted embodiment, lifting equipment 402 is equipped with acable 310 and associated coupler 309 or the like capable of liftingindividual forms via a form attachment 206 a and a coupler 309 locatedat the approximate center of gravity of form 100. One such formattachment is a one-half inch (½″) threaded shank eye bolt with ashoulder as manufactured by Chicago Hardware. Coupler 309 is passedthrough form attachment 206 a. A shackle or the like may also beutilized to more securely attach coupler 309 to form attachment 206 a.Thereafter, form 100 may be lifted from the stack of forms and/or formholder 404 and suspended over the side of the bridge relative tostructural member 302 as shown in FIGS. 3A and 3B as discussed above.Form 100 may then be secured to structural member 302 via ties 314 andform attachments 206 a as also discussed in greater detail above withrespect to FIGS. 3A through 3I.

The erection equipment allows quick installation. Further, safety isfacilitated by making a positive connection with the form before it islifted and after it is secured to the existing structure or structurebeing built. Moreover, the equipment allows a tie off point tofacilitate safety before form 100 is installed and/or duringconventional construction of the interior bridge deck bay when suchconstruction follows the installation of form 100. However, the forms ofthe present invention may be installed utilizing other methods than thatdescribed herein without departing from the scope of the presentinvention.

Turning now to FIGS. 5 through 7, depicted are perspective, plan, andside views of stay-in-place fascia form 700 having a plurality ofrecesses 703 in accordance with one alternate embodiment of the presentinvention. Recesses 703 decrease the weight of form 700. Although four(4) recesses 703 are illustrated, varying quantities may be substitutedwithout departing from the scope hereof.

In the depicted embodiment, the features of form 700 including, withoutlimitation, inserts 702, interior surface 706, bevel 712, protrusion716, and rabbet 718 are substantially identical to the equivalentcomponents of form 100, namely, inserts 202, interior surface 106, bevel212, protrusion 216, and rabbet 218 as discussed above. That is, theonly substantial difference between form 100 and form 700 is that thelatter includes recesses 703 and the dimensions thereof have beenaltered to accommodate recesses 703 while maintaining the structuralintegrity of form 700.

More specifically, height H₇ of form 700 is approximately forty oneinches (41″), width W₇ is approximately thirty seven and one half inches(37½″), and length L₁ is approximately sixty inches (60″), however,varied dimensions may be substituted to accommodate, for example,desired size of the structure being built, material strength andgeometric boundaries, and/or varying recess sizes and/or quantities.

Form 700 has a thickness T₇ of approximately three inches (3″); however,alternate thicknesses may be substituted without departing from thescope of the present invention.

As best seen in the plan view of FIG. 6, recesses 703 have a recessouter width RO of approximately ten inches (10″) and a recess innerwidth RI of approximately eight inches (8″). That is, the interiorsurfaces surrounding the perimeter of recesses 703 slope inward at anAngle A2 of approximately 45 degrees as such surfaces extend frominterior surface 706 of form 700 to interior surface 705 of recess 703.Such angle is best seen in the side view of FIG. 7. Also, the outerlatitudinal edges 707 of recesses 703 are located at a distance D_(7B)of approximately four inches from the latitudinal edges of interiorsurface 706. Similarly, the outer longitudinal edges 709 of the twooutermost recesses 703 are located at a distance D_(7A) of approximatelyfour inches from the longitudinal edges of interior surface 706.Recesses 703 have a depth RD of approximately one inch (1″). All of theaforementioned dimensions and angles illustrate one embodiment of thepresent invention, however, varying dimensions and/or angles may besubstituted without departing from the scope hereof.

Referring next to FIGS. 8A through 8C, depicted are perspective, plan,and side views of stay-in-place fascia form 800 having a pair ofapertures 803 and a recess 813 in accordance with one alternateembodiment of the present invention. Apertures 803 allow the form to besecured in place by a coupler such as a rod or the like. That is, afirst end of the coupler is coupled to the structural member on whichform 800 sits via any one of a plurality of methods known in the art.The second end of the coupler passes through a respective aperture 803.Thereafter, fasteners (e.g., nuts and bolts) may be fastened to thesecond end of the coupler to prevent or minimize the possibility of thecoupler disengaging itself from aperture 803. Although two (2) apertures803 are illustrated, varying quantities may be substituted withoutdeparting from the scope hereof.

Recesses 813 decrease the weight of form 800. Although one (1)substantially rectangular, bi-level recess 813 is illustrated, varyingquantities and/or shapes may be substituted without departing from thescope hereof.

In the depicted embodiment, the features of form 800 including, withoutlimitation, insert 802 d, interior surface 806, bevel 812, protrusion816, and rabbet 818 are substantially identical to the equivalentcomponents of form 100, namely, insert 202 d, interior surface 106,bevel 212, protrusion 216, and rabbet 218 as discussed above. That is,the only substantial difference between form 100 and form 800 is thatthe latter includes recess 813, apertures 803 in lieu of inserts 202,and the dimensions thereof have been altered.

More specifically, the height H₈ of form 800 is approximately forty oneand 5/16 inches (41⅚″), the width W₈ is approximately thirteen and 3/16inches (13 3/16″), and the length L₈ is approximately sixty inches(60″), however, varied dimensions may be substituted to accommodate, forexample, desired size of the structure being built, material strengthand geometric boundaries, and/or varying aperture sizes and/orquantities.

Form 800 has a thickness Tg of approximately two inches (2″); however,alternate thicknesses may be substituted without departing from thescope of the present invention.

As best seen in the plan view of FIG. 8B, recess 813 have a recess widthRWg of approximately fifty four inches (54″). The longitudinal edges 809of recess 813 are located approximately three inches (3″) from thelongitudinal edges of interior surface 806. Recess 813 has an overallrecess height RH₈ of approximately thirty nine and 5/16 inches (395/16″). Recess 813 includes upper and lower rectangular sections 821 and823, respectively, having recess depths RD_(8A) and RD_(8B) ofapproximately one inch (1″) and one-half inch (½″), respectively. Thewidth RW₈ of upper and lower rectangular sections 821 and 823,respectively, are both approximately fifty four inches (54″). The recessheights RH_(8A) and RH_(8B) are approximately ten and 3/16 inches (103/16″) and twenty nine and one eighth inches (29⅛″), respectively. Allof the aforementioned dimensions and angles illustrate one embodiment ofthe present invention, however, varying dimensions and/or angles may besubstituted without departing from the scope hereof.

In the depicted embodiment, the center point of each aperture 803 islocated at a height AH₈ of approximately two feet (2′)_(as) best seen inFIG. 8C. Additionally, the center points of the two apertures 803 arelocated at a distance AD₁ of approximately thirty inches (30″) from eachother and at a distance AD₂ of approximately fifteen inches (15″) fromthe longitudinal edge of interior surface 806 and a distance AD₃ ofapproximately twelve inches from longitudinal edge 809 of recess 813 asdepicted in FIG. 8B. However, varying locations and/or quantities ofaperture 803 may be substituted without departing from the scope hereof.

As best seen in FIG. 8C, apertures 803 have a frusto-conical shape,however, varying shapes may be substituted without departing from thescope hereof.

Turning now to FIGS. 9A through 9C, depicted are perspective, plan,side, and cross-sectional views of stay-in-place fascia form 900 havinga plurality of vertical recesses 903 and a horizontal recess 913 inaccordance with one alternate embodiment of the present invention.Recesses 903 and 913 decrease the weight of form 900. Although nineteen(19) vertical recesses 903 and one (1) horizontal recess 913 areillustrated, varying quantities may be substituted without departingfrom the scope hereof.

In the depicted embodiment, the features of form 900 including, withoutlimitation, inserts 902, horizontal component 904, interior surface 906,bevel 912, protrusion 916, and rabbet 918 are substantially identical tothe equivalent components of form 100, namely, inserts 202, horizontalcomponent 104, interior surface 106, bevel 212, protrusion 216, andrabbet 218 as discussed above. That is, the only substantial differencebetween form 100 and form 900 is that the latter includes verticalrecesses 903, horizontal recess 913, and the dimensions thereof havebeen altered to accommodate recesses 903 and 913 while maintaining thestructural integrity of form 900.

More specifically, height H₉ of form 900 is approximately forty oneinches and five sixteenths inches (41 5/16″), width W₉ is approximatelytwenty five inches (25″), and length L₉ is approximately sixty inches(60″), however, varied dimensions may be substituted to accommodate, forexample, desired size of the structure being built, material strengthand geometric boundaries, and/or varying recess sizes and/or quantities.

Form 900 has a thickness T₉ of approximately two inches (2″); however,alternate thicknesses may be substituted without departing from thescope of the present invention.

As best seen in the plan view of FIG. 9B, vertical recesses 903 have arecess width RW_(9V) of approximately three quarters of an inch (¾″) anda semicircular cross section, the latter of which is best seen in thecross-sectional view of FIG. 9D. The longitudinal centerlines of eachvertical recess 903 are located equidistantly at a distance D_(9A) ofapproximately three inches (3″) from all other recess longitudinalcenterlines and the longitudinal edges of interior surface 906. Also,the outer latitudinal edges 907 of vertical recesses 903 are located ata distance D_(9B) of approximately four inches from the latitudinaledges of interior surface 906. Similarly, as also stated above, theouter longitudinal edges 909 of the two outermost recesses 903 arelocated at a distance D_(9A) of approximately four inches from thelongitudinal edges of interior surface 906. Recesses 703 have a depthRD_(9V) of approximately three eighths of an inch (⅜″) and a heightRH_(9V) of approximately twenty five and one-sixteenth inches (251/16″). All of the aforementioned dimensions and angles illustrate oneembodiment of the present invention, however, varying dimensions and/orangles may be substituted without departing from the scope hereof.

As best seen in the perspective and side views of FIGS. 9A and 9C,recess 913 is located in horizontal component 904 and has a lengthapproximately equivalent to the length L₉ of form 900. The width ofrecess 913 extends from the distal longitudinal edge 907 of horizontalcomponent 904 inward at a width RW_(9H1) of approximately fourteen andone quarter inches (14¼″). Recess side surface 915 is angled downward asit extends outward at an angle of approximately 45 degrees (45°),thereby decreasing the width of recess 913 to a width RW_(9H2) ofapproximately thirteen and three quarters inches (13¾″) on itsbottommost surface. The recess height RH_(9H) is one half inch (½″). Allof the aforementioned dimensions and angles illustrate one embodiment ofthe present invention, however, varying dimensions and/or angles may besubstituted without departing from the scope hereof.

Turning next to FIGS. 10A through 10G, depicted is an exemplaryalternate stay-in-place form 1000 in accordance with one alternateembodiment of the present invention. Form 1000 is mounted parallel to,and tied atop, a structural member 302, as discussed hereinabove. Thisexemplary form 1000 is utilized as a form for supporting uncuredconcrete, and, after the concrete has cured, form 1000 remains anintegral part of the structure formed thereby. This exemplary form 1000is intended for uses similar to the uses of form 100, and providessimilar benefits to form 100, as described in greater detail above.

Similar to form 100, form 1000 is a relatively thin, substantiallyL-shaped panel that includes vertical component 1002 and horizontalcomponent 1004. In the depicted embodiment, vertical component 1002 islocated substantially perpendicular to horizontal component 1004,however, alternate orientations may be substituted.

Vertical component 1002 and the proximal portion of horizontal component1004 have thicknesses T₁ of approximately three inches (3″). Thethickness T₂ of the distal end of horizontal component is thicker (i.e.,three and seven thirty seconds (3 7/32) inches), however, alternatethicknesses may be substituted without departing from the scope of thepresent invention. That is, in the depicted embodiment, the thickness ofhorizontal component 1004 gradually increases starting at itsintersection with joining component inwardly facing surface 1234,however, alternate sizing and configurations may be substituted withoutdeparting from the scope hereof.

The height H₁₀₀₀ of form 1000 is approximately forty inches (40″), thewidth W₁₀₀₀ is approximately fifteen and thirty-five hundredths inches(15.35″), and the length L₁₀₀₀ is approximately sixty inches (60″),however, varied dimensions may be substituted to accommodate, forexample, desired size of the structure being built as well as materialstrength and geometric boundaries.

In the depicted embodiment, the features of form 1000 including, withoutlimitation, insert 1202 d, vertical component interior surface 1006,bevel 1212, vertical component upwardly facing surface 1222, horizontalcomponent upwardly facing surface 1008, vertical component inwardlyfacing surface 1110, joining component inwardly facing surface 1234,joining component 1210, ornamental features 1240, horizontal componentdownwardly facing surface 1114, and protrusion 1216 are substantiallyidentical to the equivalent components of form 100, namely, insert 202d, interior surface 106, bevel 212, upwardly facing surface 222,upwardly facing surface 108, inwardly facing surface 110, inwardlyfacing surface 234, joining component 210, ornamental features 240,downwardly facing surface 114, and protrusion 216 as discussed abovewith the following exceptions.

Rabbet 1218 is substantially identical to rabbet 218 of form 100 withthe exception of top and side surfaces 1050 and 1052, respectively. Morespecifically, in the embodiment of the present invention depicted inFIGS. 10A through 10K, as best seen in FIG. 10E, the rabbet 1218includes a rabbet 1218 defined by top and side surfaces 1050 and 1052,respectively. Side surface 1052 tapers inwardly as it extends downwardlyat an angle of approximately fifteen and one half (15.5) degrees beyondvertical, and top surface 1050 tapers upwardly as it extends distallyaway from side surface 1052 at an angle of approximately fifteen and onehalf (15.5) degrees above horizontal. Consequently, the top and sidesurfaces 1050 and 1052 are located at an angle of greater than ninetydegrees relative to each other. Also, each of top and side surfaces 1050and 1052, respectively, are located at an angle of greater than ninetydegrees relative to the vertical and horizontal planes 1059 and 1057,respectively, of the innermost point 1055 of the rabbet 1218. That is,top surface 1050 is greater than ninety degrees relative to the verticalplane 1059 of point 1055, and side 1052 is greater than ninety degreesrelative to the horizontal plane 1057 of innermost point 1055. However,alternate angles and/or configurations for the sides of rabbet 1218 maybe substituted without departing from the scope hereof. Rabbet 1218 mayalso have varying cross-sections without departing from the scopehereof, including, without limitation, a square cross-section.

Also, in the depicted embodiment of the present invention, the uppercorner of a distal end of horizontal component 1004 is in the form ofchamfered edge 1214 rather than the rounded edge 214 shown for form 100.Further, chamfered edge 1214 is chamfered at an angle of approximatelyforty-five degrees relative to horizontal component upwardly facingsurface 1008 and horizontal component distal vertical surface 1054,however, alternate angles may be substituted without departing from thescope hereof. However, alternate configurations and/or shapes for thisedge may be substituted including, without limitation a squared edge, arounded edge or edge treatment.

Additionally, form 1000 includes internal reinforcement 1056 as depictedin FIG. 10H and similar to internal reinforcement 242 of form 100. Inthe depicted embodiment, internal support 1056 is a four (4) inch byfour (4) inch grid of welded wire mesh W4.0 by W4.0 Grade 60 GalvanizedSteel ASTM Designation A 185 A 641, located internal to form 1000 asdepicted in dashed lines in FIGS. 10A and 10C through 10E. As seen inFIG. 10E, internal reinforcement 1056 is substantially horizontalinternal to horizontal component 1004 until a point slightly distal toinsert 1202 c, at which point it angles upwardly as it approaches thedistal end of substantially horizontal component 1004 at an angle thatretains internal reinforcement 1056 at the vertical midpoint ofhorizontal component 1004. However, alternate angles, internalreinforcements and/or internal reinforcement configurations may besubstituted without departing from the scope hereof. Or, internalreinforcement may be omitted partially or entirely without departingfrom the scope hereof.

Further, in form 1000, similar to form 100, the inserts 1202 of thesubstantially horizontal component 1004 and the substantially verticalcomponent 1002 facilitate attachment of form 1000 to an existingstructural member 302. However, the attachment mechanism 1060 utilizedin conjunction with such form attachments differ.

More specifically, in the depicted embodiment, attachment mechanism 1060includes, primary support 1253, secondary support 1254, primary tiesystem 1298, and secondary tie system 1252. In the depicted embodiment,primary tie system 1298 includes, rod 1249, rod insert 1250 a,adjustable fastener 1251, and form attachment 1206 a which are coupledto form 1000 and the top of structural member 302 diagonally at an angleof approximately forty-five (45) degrees, however alternate angles maybe substituted without departing from the scope hereof.

In the depicted embodiment, the primary tie system 1298 includes atleast one coil rod 1249 such as an inline, Dayton Superior B12 coil rodmade of a rigid material such as steel etc. having a one-half (½) inchdiameter capable of withstanding a load of at least 18,000 pounds. Oneend of rod 1249 is connected to rod insert 1250 b of primary support1253 and the other end of rod 1249 is connected to rod insert 1250 a.The rod inserts 1250 a and 1250 b are constructed of a rigid materialsuch as steel and the like and have a diameter of one half (½) inch andlength of six (6) inches. In the depicted embodiment, these rod insertsare Dayton Superior one half inch (½″) diameter by six inch (6″) lengthB16 coil loop inserts.

Rod insert 1250 a is connected to form 1000 by means of an adjustablefastener 1251 and form attachment 1206 a. In the depicted embodiment,adjustable fastener 1251 is a turnbuckle with jaw ends made of a rigidmaterial such as steel etc. and having a three quarter (¾) inchdiameter, and form attachment 1206 a is in the form of a one half (½)inch diameter shoulder eyebolt (also made of a rigid metal such as steeletc.) affixed to form 1000 by insertion into insert 1202 d. Adjustablefastener 1251 allows the spacing connection between form attachment 1206a and rod 1249 to be fine-tuned by spinning it in either direction toengage the threads, which may be used, for example, to bring the forminto a plumb position. This may be done via a wrench or the like.

Rod insert 1250 b is integral to primary support 1253 as shown in FIG.10B. In the depicted embodiment, primary support 1253 includes twosubstantially rectangular bent plates, namely, upper and lower plates1246 and 1245, respectively. The downwardly facing surface 1280 of theproximal end of upper plate 1246 is welded to the upwardly facingsurface 1282 of the proximal end of lower plate 1245. However, alternateembodiments are envisioned in which the welding is eliminated and twoseparate plates are utilized and are held together via a fastener suchas fastener 1251.

Upper and lower plates 1246 and 1245, respectively, have substantiallyrectangular shapes and are made of a rigid metal such as, but notlimited to, steel. In the depicted embodiment, upper bent plate 1246 isfour (4) inches wide, ten (10) inches long, and one half (½) inch thick,and it is bent at an angle of approximately forty-five (45) degreesrelative to its longitudinal axis to receive and accommodate diagonallypositioned primary tie system 1298, however alternate angles may besubstituted without departing from the scope hereof. Lower plate 1245 isalso substantially rectangular and made of a rigid material such as, butnot limited to, ½-inch thick steel and having dimensions of two and onesixteenth (2 1/16) inches wide and seven and one quarter (7¼) incheslong. In the depicted embodiment, lower plate 1245 is bent at an angleof approximately twenty-two and one half (22½) degrees from itslongitudinal axis to receive and accommodate the position of secondarytie system 1252, which in the depicted embodiment is a secondary supportrod. However alternate angles may be substituted without departing fromthe scope hereof.

As seen in the top view of FIG. 10I, upper plate 1246 includes anaperture 1284 at its proximal end. As seen in FIG. 10F, similarly, lowerplate 1245 includes an aperture 1288 at its proximal end. In thedepicted embodiment, as seen in FIG. 10B, rod insert 1250 b is connectedto a distal end of upper plate 1246 by means of a fillet weld, and rodinsert 1241 is connected to a distal end of lower plate 1245 by means ofa fillet weld.

Primary support 1253 is coupled to structural member 302 by means offastener 1251. In the depicted embodiment, fastener 1251 is a threadedshear stud being made of a rigid material such as steel and the likewelded to structural member 302. The apertures of upper and lower plates1246 and 1245, respectively, are passed over the stud and a nutcompatible with the threaded end of the stud is fastened atop upperplate 1246 to hold primary support 1253 in place relative to structuralmember 302 therewith. However, alternate sizes for upper bent plate 1246and lower bent plate 1245, and alternate methods of attaching suchplates to the structural member 302, to rod insert 1250 b, and to eachother may be substituted without departing from the scope hereof.

In the depicted embodiment, secondary tie system 1252 may be a coil rodsimilar to rod 1249 of primary tie system 1298, however, alternate tiesor supports may be substituted.

In the depicted embodiment, as shown in FIG. 10F, secondary support 1254is substantially rectangular, made of a rigid metal such as steel andhas two apertures 1288 and 1290 at either end. In the depictedembodiment, secondary support 1254 is bent at an angle of approximatelytwenty-two and one half (22½) degrees from its longitudinal axis toreceive and accommodate the position of secondary tie system 1252,however alternate angles may be substituted without departing from thescope hereof.

Secondary support 1254 is coupled to the upwardly facing surface 1008 ofhorizontal member 1004 via a fastener 1292 passing through aperture 1288and into insert 1202 c. For example, fastener 1292 may be a one half (½)inch diameter bolt.

Secondary tie system 1252 is attached at a first end by insertion and/orthreading of secondary tie system into rod insert 1241. The second endof secondary tie system 1252 is passed through an aperture 1290 insecondary support 1254 and a retention mechanism 1292 is threaded ontothe second end of secondary tie system 1252 until it is in contact withsecondary support 1254, thereby holding secondary tie system 1252 inplace. Retention mechanism may be a nut or the like.

Although the depicted attachment mechanism 1060 includes, primarysupport 1253, secondary support 1254, primary tie system 1298, andsecondary tie system 1252, alternate attachment mechanisms 1060 areenvisioned. For example, secondary support 1254 and secondary tie system1252 may be omitted. Or, primary support 1253 and primary tie system1298 may be omitted. Alternatively, various components of the attachmentmechanism 1060 may be substituted for other components having equivalentfunctionality. And alternate methods of coupling the components ofattachment mechanism 1060 may be substituted without departing from thescope hereof.

After form 1000 is tied in place, it contains the work area as soon asit is installed as discussed, which minimizes or eliminates fallhazards, thereby eliminating the time, costs (e.g., labor costs, removalcosts, disposal costs, etc.), and downtime associated with installationof safety measures that are typically required (e.g., formwork,scaffolding, road closure, etc.) to contain the work area. The exposedties having a load rating well-over that required to temporarily anchorfall protection life lines. Minimal or zero excess materials are neededto contain the work area since the form performs this task while alsoremaining in place after construction to become part of the structurebeing built. Also, the disruption of traffic or other environmentalconsiderations beneath the structure being built is minimized as allwork can be safely performed from atop the structure.

After the form 1000 is installed as depicted in FIG. 10C, the process ofinstalling the deck and barrier may proceed as described above withrespect to FIGS. 3A through 3I with the following modifications.

After the concrete is poured and cured, the portion of attachmentmechanism 1060 located above the deck which is not going to be encasedin the barrier may optionally be removed from the form 1000 viadismantling turnbuckle with jaw ends 1251 from form attachment 1206 a onone end and rod insert 1250 a on the opposite end. The rod insert 1250 aand form attachment 1206 a may need to be cut away from the newly formeddeck by means of a grinder and the like. Alternatively, they may be leftin place and encased in the overall deck and barrier combination. Theencasement of form 1000 facilitates the ability of form 1000 toaccommodate the shear and moment forces placed thereupon by the weightof the overall deck and barrier.

Referring now to FIG. 10J, depicted is an enlarged side view of thedistal end of the horizontal component of the form of FIG. 10A having analternate distal end in which the upwardly facing surface 1008 anglesupwardly as it extends outwardly and away from joining component 1210 ata greater angle than that shown in FIGS. 10A through 10I. By angling theheight of upwardly facing surface 1008 at a greater angle relative tojoining component 1210, the thickness of the distal end of horizontalcomponent 1004 is increased as compared to the distal end of thehorizontal component shown in FIGS. 10A through 10I. A thicker distalend may be desirable, for example, when a structural support such asstructural support 1302 has a varied flange thickness (i.e., the bottomof the top flange remains constant while the top of the flange steps upor down). Since standard construction practice is to hold the bottom ofform 1000 even with the bottom of the top flange, the edge of the form1000 needs to be thickened so that the notch can be blocked out duringcasting in essence putting a step in form 1000 along its edge to mimicthe geometry of the structural support 1302 while maintaining at leastone and a half inches (1½″) of concrete cover above the notch area totake the load. FIG. 10J depicts one method of accounting for suchconcrete cover. Another example is shown in FIG. 10K in which the distalend is thickened but, in lieu of a continuously upwardly angled slope toupwardly facing surface 1008, form 1000 includes a transitional surface1062 that transitions from the upwardly facing surface 1008 of thethickened distal end to the area proximal to the thickened end at anangle of approximately forty five degrees. In this manner, the distalend of horizontal component 1004 is thickened while maintaining theproximal portion of horizontal component at a thickness more similar tothat of the joining component 1210 interface. However, alternate methodsof thickening the distal end of horizontal component 1004 may besubstituted without departing from the scope hereof.

Turning now to FIGS. 11A through 11F, depicted is yet another exemplaryalternate stay-in-place form 11000 in accordance with an alternateembodiment of the present invention, the form mounted parallel to, andtied atop, a concrete structural member 11102 having a substantiallyrectangular cross-section. This exemplary form 11000 is utilized as aform for supporting uncured concrete, and, after the concrete has cured,form 11000 remains an integral part of the structure formed thereby.This exemplary form 11000 is intended for uses similar to the uses offorms 100 and 1000, and provides similar benefits to forms 100 and 1000,as described in greater detail above.

Similar to form 1000, form 11000 is a relatively thin, substantiallyL-shaped panel that includes vertical component 11002 and an extremelyminimal horizontal component 11004. In the depicted embodiment, verticalcomponent 11002 is located substantially perpendicular to horizontalcomponent 11004, however, alternate orientations may be substituted.

Vertical component 11002 has a thickness T₁₁₀₀ of approximately two andone quarter inches (2¼″). The thickness T₁₁₀₁ of horizontal component1104 is thicker (i.e., approximately three (3) inches), however,alternate thicknesses may be substituted without departing from thescope of the present invention.

In the depicted embodiment, the features of form 11000 including,without limitation, insert 11202, bevel 11212, vertical componentupwardly facing surface 11222, form inwardly facing surface 11010,joining component inwardly facing surface 11234, joining component11210, ornamental feature 11240, downwardly facing surface 11114, andrabbet 11218 are substantially identical to the equivalent components ofform 1000, namely, insert 1202, bevel 1212, upwardly facing surface1222, inwardly facing surface 1010, inwardly facing surface 1234,joining component 1210, ornamental feature 1240, downwardly facingsurface 1114, and rabbet 1218 as discussed above with the followingexceptions.

In the depicted embodiment, as best seen in FIG. 11B, form 11000includes a plurality of inserts 11202 e recessed in the upper edge ofvertical component outwardly facing surface 11006 of vertical component11002. Inserts 11202 e are similar to inserts 202 as described ingreater detail herein with regards to form 100. In the depictedembodiment, as depicted in FIG. 11D, inserts 11202 e are locatedapproximately two (2) feet from each other horizontally andapproximately six (6) inches from the lateral sides of form 11000.Inserts 11202 e facilitate the attachment of an external, removable formsuch as secondary form 11500 that allows the concrete barrier 11502 tobe poured over the top of form 11000 as shown in FIG. 11E. Removablesecondary form 11500 may be coupled to form 11000 with any formattachment 11206 compatible with insert 11202 e including, withoutlimitation, bolts or the like. In the depicted embodiment, removableform 11500 has a substantially rectangular body 11508 with asubstantially rectangular cross section as well as a lower band 11504coupled to the bottom interior of the rectangular body. Lower band 11504has an angled upwardly facing surface 11506 that extends upwardly at anangle of approximately forty five (45) degrees as it extends outwardlyaway from form 11000. The innermost, bottommost edge of band upwardlyfacing surface 11506 is in contact with the outermost, bottommost edgeof primary form upwardly facing surface 11222 such that a channel isformed therebetween. When this channel is filled with concrete and suchconcrete cures, a concrete decorative panel is formed atop the outwardlyfacing surface of form 11000 for aesthetic purposes. However alternatelyconfigured secondary forms and form liners may be substituted withoutdeparting from the scope hereof including, without limitation, forms ofdifferent materials and different shapes.

Similar to form 1000, form 11000 is secured in place to concretestructural member 11102 via an attachment mechanism 11060 that includesprimary supports 11253, secondary supports 11254, primary tie system11298, and secondary tie system 11252. However, such supports vary insome manners from those utilized for form 11000.

First, primary support 11253 utilized with form 11000 includes a singleplate 11246 a only and rather than upper and lower plates. The angle ofthe bend in plate 11246 may be adjusted as needed to accommodate theangle at which the primary tie system 11298 will be installed. Primarysupport 11253 couples to concrete structural member 11102 via insertionof a form attachment 11206 f such as a screw, bolt or the like throughthe aperture 11284 in plate 11246 a into the concrete structural member,or an insert placed therein, wherein the head of the screw, bolt, or thelike is larger than the aperture, thereby holding plate 11246 a inplace.

Primary tie system 11298 is substantially identical to primary tiesystem 12298, as described with reference to FIG. 12B, however, itattaches on its upper end to form 11000 via a plate 11246 b rather thana coil loop and eye bolt style form attachment. Plate 11246 b issubstantially identical to plate 11246 a and it couples to form 11000 inthe same manner with which plate 11246 a couples to concrete structuralmember 11202, however the angle of the bend in plate 11246 b may beadjusted to accommodate the angle of the primary tie system 11298.

Also, secondary supports 11254 differs from secondary support 1254 asshown in FIG. 11F. Secondary support 11254 is an L shaped bracket havinga base aperture 11286 that is substantially centered in base 11287 and awall aperture 11284 that is substantially horizontally centered in wall11285 at an upper end thereof. As also seen in FIG. 11F, secondarysupport is coupled to a concrete structural member 11102, or an insertrecessed therein, via a fastener or form attachment 11289 such as a boltand washer or a screw. Secondary tie system 11252 is attached to form11000 via passing a first end of rod 11252 through wall aperture 11284(such that rod 11252 is substantially parallel to concrete structuralmember 11102), and then threading it into an insert 11202 recessed inform 11000 as shown in FIG. 11F. Inserts 11202 are similar to thosedescribed in greater detail hereinabove with regards to inserts 202.After such threading, secondary tie system 11252 is further coupled tosecondary support 11254 via the threading of a secondary tie systemfastener 11290 to a second end of secondary tie system 11252 until thefastener is in contact with an outwardly facing surface 11291 of wall11285. Secondary tie system fastener may be, for example, a washer and anut as shown in FIG. 11F.

After the form 11000 is installed as depicted in FIG. 11A, the processof installing the deck and barrier may proceed as described above withrespect to FIGS. 3A through 3I with the following modifications. Afterthe deck concrete is poured and cured, the portion of attachmentmechanism 11060 located above the deck and which is not going to beencased in the barrier may optionally be removed from the form 11000 viadismantling adjustable fastener 11251 from upper plate 11246 on one endand rod insert 11250 a on the opposite end. The rod insert 11250 a andupper plate 11246 may need to be cut away from the newly formed deck bymeans of a grinder and the like. Alternatively, they may be left inplace and encased in the overall deck and barrier combination. Theencasement of form 11000 facilitates the ability of form 11000 toaccommodate the shear and moment forces placed thereupon by the weightof the overall deck and barrier.

Further, when the concrete for the barrier is poured, it is poured to aheight that is higher than the upwardly facing surface 11222 of form11000, and is held in place by removable form 11508. In this manner, thebarrier is poured over form 11000. After the concrete is cured, theremovable form 11508 is then removed from the outwardly facing surfaceof form 11000.

Referring next to FIGS. 12A through 12C, depicted is yet anotherexemplary alternate stay-in-place form 12000 in accordance with analternate embodiment of the present invention, the form mounted parallelto, and tied atop, a structural member 302 as discussed in greaterdetail above. This exemplary form 12000 is utilized as a form forsupporting uncured concrete for a deck only (e.g., in an embodiment inwhich there is a steel railing with a sidewalk or safety walk in lieu ofa concrete barrier), and, after the concrete has cured, form 12000remains an integral part of the structure formed thereby. This exemplaryform 12000 is intended for uses similar to the uses of forms 100, 1000,and 1100, and provides similar benefits to such forms, as described ingreater detail above with the modifications described herein.

Similar to form 1000, form 12000 is a relatively thin, substantiallyL-shaped panel that includes a relatively short vertical component 12102and a longer horizontal component 12104. In the depicted embodiment,vertical component 12102 is located substantially perpendicular tohorizontal component 12104, however, alternate orientations may besubstituted.

In the depicted embodiment, the features of form 12000 including,without limitation, insert 12202, form interior surface 12006, bevel12212, vertical component upwardly facing surface 12222, verticalcomponent inwardly facing surface 12010, joining component inwardlyfacing surface 12234, joining component 12210, horizontal componentdownwardly facing surface 12114, and rabbet 12218 are substantiallyidentical to the equivalent components of form 1000, namely, insert1202, form interior surface 1006, bevel 1212, vertical componentupwardly facing surface 1222, vertical component inwardly facing surface1010, joining component inwardly facing surface 1234, joining component1210, horizontal component downwardly facing surface 1114, and rabbet1218 as discussed above with the following exceptions.

In the depicted embodiment, form 12000 is mounted parallel to, and tiedatop, structural member 302. As shown in FIG. 12A, form 12000 issupported by at least one pair of L-shaped brackets 12206 a and 12206 b.Each bracket 12206 is formed from a pair of bracket sections 12208 a and12208 b, which may be made of a rigid material such as steel or thelike. Second bracket section 12208 b is oriented perpendicular to thevertical axis of structural member 302. First bracket section 12208 a isdisposed vertically at the distal end of second bracket section 12208 b,and its bottommost end is welded to the distal end of second bracketsection 12208 b such that the first and second bracket sections togetherform a substantially ninety (90) degree angle cradle capable of holdingform 12000 in place thereupon. In the depicted embodiment, the angle isninety (90) degrees, however alternate angles may be substituted withoutdeparting from the scope hereof. Also, varying quantities of bracketsand bracket sections, as well as brackets having differingconfigurations, may be substituted without departing form the scopehereof.

Brackets 12206 are connected to structural member 302 and form 12000 viaattachment mechanism 12060. In the depicted embodiment, attachmentmechanism 12060 is substantially identical to attachment mechanism 1060as described above with the exception of the primary tie system 12298.As best seen in FIG. 12B, primary tie system 12298 includes two threadedrods 12249 a and 12249 b (e.g., inline, Dayton Superior threaded metalrods having a ¾-inch diameter capable of withstanding a load of at least18,000 lbs), which are coupled to substantially vertical first bracketsection 12208 a and structural member 302 in a diagonal fashion.

A first rod 12249 a has a first threaded end that is connected toapertures in substantially vertical first bracket section 12208 a bymeans of fastener 12210. In the depicted embodiment, fastener 12210 is awasher and coil nut, however, alternate fasteners may be substitutedwithout departing from the scope hereof. A second end of first rod 12249a is connected to a first end of second rod 12249 b via an adjustablefastener 12250. In the depicted embodiment, adjustable fastener 12250 isa cylinder-shaped, strut coil tie with a ¾-inch diameter and six-inchlength. Adjustable fastener 12250 allows the spacing between rods 12249a and 12249 b to be adjusted via rotation of adjustable fastener 12250in either of two directions, typically via a wrench. The adjustablefastener facilitates placing the form 12000 in a substantially plumbposition. A second end of second rod 12249 b is coupled to a coil loop12251, which is welded to upper plate 12246 in the same manner discussedabove with respect to upper plate 1246 as shown in FIG. 10B.

Another difference in the form 12000 as compared to form 1000 is thatthe horizontal component 12104 includes horizontal component apertures12502 in lieu of inserts 1202 c. These apertures 12500 allow secondarysupport 12254 to be coupled to horizontal member 12104 and secondbracket section 12208 b via passage of a fastener 12503 (e.g., a boltwith a washer) through secondary support aperture 12500, horizontalcomponent aperture 12502, and second bracket section aperture 12504 toconnect all three components to each other, sandwiching form 12000between secondary support 12254 and second bracket section 12208 b. Insome embodiments, the fastener 12502 is configured to receive a hollowplastic sleeve 12240 to create a small tunnel to allow access to thefastener 12503 after the poured deck cures.

Additionally, as seen in FIG. 12C, another variation of form 12000 isthat a channel 12216 is substituted in lieu of a protrusion 216 asdiscussed above with respect to form 100. As best seen in FIG. 12C,channel 12216 is recessed longitudinally along the length of form 12000directly below joining component 12234. Channel 12216 has asubstantially triangular cross-section, with both internal sidesoriented at an angle of forty five (45) degrees relative to the verticalmidpoint of the channel. Channel 12216 acts as a drip strip to causewater to drip downward rather than along downwardly facing surface12114. Channel 12216 and bevel 12212 both act to eliminate or minimizethe amount of water that reaches structural support 302 in an effort tominimize corrosion thereof. However, alternate configurations,locations, and/or shapes for this channel may be substituted, or channel12216 may be omitted, without departing from the scope hereof.

After the form 12000 is installed as depicted in FIGS. 12A and 12B, theprocess of installing the deck may proceed as described above withrespect to FIGS. 3A through 3I (except that no barrier is poured). Afterthe deck concrete is poured and cured, the portion of attachmentmechanism 12060 located above the deck and which is not going to beencased in the deck may be removed from the form 12000 via dismantlingadjustable fastener 12250 from its adjacent rods 12249 a and 12249 b.The rods 12249 a and/or 12249 b may need to be cut away from the newlyformed deck by means of a grinder and the like. Additionally, thebrackets 12206 are removed from form 12000, the latter remaining inplace internal to the poured deck. The encasement of form 12000 in thepoured deck facilitates the ability of form 12000 to accommodate theshear and moment forces placed thereupon by the weight of the overalldeck.

Turning now to FIGS. 13A through 13F, depicted is an exemplary alternatestay-in-place fascia form 13000 in accordance with one alternateembodiment of the present invention, the form mounted parallel to, andtied atop, structural member 302. This exemplary form 13000 is utilizedas a form for supporting uncured concrete, and, after the concrete hascured, form 13000 remains an integral part of the structure formedthereby. This exemplary form 13000 is intended for uses similar to theuses of the other forms discussed herein, and provides similar benefitsto such forms, as described in greater detail above.

Similar to form 100, form 13000 is a relatively thin, substantiallyL-shaped panel that includes vertical component 13002 and horizontalcomponent 13004. In the depicted embodiment, vertical component 13002 islocated substantially perpendicular to horizontal component 13004,however, alternate orientations may be substituted.

Vertical component 13002 and the proximal portion of horizontalcomponent 13004 have thicknesses similar to the thicknesses of form 1000as discussed in greater detail above. The height H₁₃ and width W₁₃ ofform 13000 is approximately forty eight inches (48″), and the length L₁₃is approximately sixty inches (60″), however, varied dimensions may besubstituted to accommodate, for example, desired size of the structurebeing built as well as material strength and geometric boundaries.

In the depicted embodiment, the features of form 13000 including,without limitation, insert 13202, form attachment 13206, form interiorsurface 13006, bevel 13212, vertical component upwardly facing surface13222, vertical component inwardly facing surface 13010, joiningcomponent inwardly facing surface 13234, joining component 13210,horizontal component downwardly facing surface 13114, and rabbet 13218are substantially identical to the equivalent components of form 1000,namely, insert 1202, form attachment 1206, form interior surface 1006,bevel 1212, vertical component upwardly facing surface 1222, verticalcomponent inwardly facing surface 1010, joining component inwardlyfacing surface 1234, joining component 1210, horizontal componentdownwardly facing surface 1114, and rabbet 1218 as discussed above withthe exceptions of the attachment mechanism 13060.

The attachment mechanism 13060 depicted in FIGS. 13A-13C may be used,for example, with large forms that have large overhangs relative tostructural member 302 due to factors including, but not limited to, thesize of horizontal component 13004. In the depicted embodiment,attachment mechanism 13060 incorporates a strut style secondary tiesystem 13252 to help reduce and distribute the stress placed on the form13000.

As depicted in FIGS. 13A and 13B, each form 13000 incorporates a pair ofattachment mechanisms 13060 for coupling form 13000 to structural member302. Further, each attachment mechanism 13060 includes primary support13253, secondary support 13254, primary tie system 13298, and secondarytie system 13252. Primary tie system 13298 includes a pair of threadedtie back rods 13282 installed diagonally, made of a rigid material suchas steel, and sized for a load of, for example, at least 95,000 lbs. Afirst end of primary tie system 13298 is coupled to form 13000 viainsert 13202 and a form attachment 13206 such as an eyebolt, anchor rodor the like. Insert 13202 and form attachment 13206 at a point above thevertical midpoint of vertical component 13002. A second end of primarytie system 13298 is attached to structural support 302 via a pair ofprimary supports 13253.

In the depicted embodiment, primary support 13253 includes a primaryfastener 13284, plate 13285, plate body fastener 13287, and plate basefastener 13286. As shown in FIG. 13C, the second end of each primarysupport 13253 is coupled to a respective primary fastener 13284. In thedepicted embodiment, primary fastener 13284 is a clevis constructed of aone half (½) inch rigid material such as Grade 50 steel and the likewith an aperture 13297 having a diameter of seven eighths (⅞) inch. Theprimary fastener 13284 has a threaded aperture 13288 for engaging thethreaded end of the respective tie back rod 13282. The tie back rod13282 and primary fastener 13284 connect to existing structural member302 by means of a rectangular, bent plate 13285 with a length of nineand one quarter (9¼) inches, a width of four (4) inches, and a thicknessof one half (½) inch. However, the dimensions of plate 13285 may varydepending upon, for example, the governmental standard being met (e.g.,OSHA 4:1 Failure (ULT), AASHTO ASD and 2:1 (ULT), AISC ASD AND 2:1(ULT)). Plate 13285 is made of a rigid material such as Grade 50 steeland the like and has base and body apertures 13298 and 13299,respectively. In the depicted embodiment, the body 13400 of plate 13285is bent at an angle A₁ of approximately twenty-five (25) degreesrelative to the longitudinal axis of body 13400 of plate 13285. Also,base 13402 has a length L₁₁ of approximately three and one quarter (3¼)inches, and the body 13400 has a length L₁₂ of approximately four and aquarter (4¼) inches with a bend length L₁₃ of approximately one andthree quarters (1¾) inch, however, alternate angles, lengths, and/orother dimensions may be substituted to accommodate, for example, varyingsizes of forms.

Plate 13285 is coupled to structural member 302 via sliding baseaperture 13298 of plate 13285 over a seven-eighths (⅞) inch threadedshear stud welded to the structural member 302. A nut is then threadedover the stud until it contacts the upwardly facing surface of the baseof plate 13285 in order to secure the plate 13285 to the structuralmember 302.

Also, the clevis 13284 is slid over the body of plate 13285 until itsapertures 13297 align with body aperture 13299 of plate 13285.Thereafter, fastener 13287 is passed therethrough to couple primaryfastener 13284 and the coupled primary support to plate 13285. In thismanner, each tie back rod 13282 is coupled to structural member 302.Fastener 13287 is in the form of a clevis bolt and respective nut,however, alternate fasteners may be substituted.

Thereafter, or prior to such attachment, secondary tie system 13252 maybe installed. In the depicted embodiment, secondary tie system includesa strut such as an interior angle strut, which may be installed via aform attachment coupled to an insert as described in greater detailherein. Or, in some instances, screws or the like may be drilleddirectly into form 13000.

Turning now to FIG. 13D, depicted is an alternate primary support 13653,which includes a primary fastener 13684, plate 13685, and plate basefastener 13686. As shown in FIG. 13D, the second end of each primarysupport 13653 is coupled to a respective primary fastener 13684. In thedepicted embodiment, primary fastener 13684 is a seven-eighths inch (⅞″)diameter by two and one half inches (2½″) long coupler nut which iswelded to plate 13685. The primary fastener 13684 has a threadedaperture 13688 for engaging the threaded end of the respective tie backrod 13282. Fastener 13684 is in the form of a coupler nut welded toplate 13685, however, alternate fasteners may be substituted.

The tie back rod 13282 and primary fastener 13684 connect to existingstructural member 302 by means of a rectangular, bent plate 13685 with alength of nine and one quarter (9¼) inches, a width ranging from threeinches (3″) to four and three quarters inches (4¾″), and a thickness ofone (1) inch. However, the dimensions of plate 13685 may vary dependingupon, for example, the governmental standard being met (e.g., OSHA 4:1Failure (ULT), AASHTO ASD and 2:1 (ULT), AISC ASD AND 2:1 (ULT)). Theplate 13685 is made of a rigid material such as Grade 50 steel and thelike and has base aperture 13698. In the depicted embodiment, the body13600 of plate 13685 is bent at an angle A₁ of approximately twenty-five(25) degrees relative to the longitudinal axis of base 13602 of plate13685. Also, base 13602 has a length L₁₁ of approximately three andthree eighths (3⅜) inches, and the body 13600 has a length L₁₂ ofapproximately three and one sixteenth (3 1/16) inches with a bend lengthL₁₃ of approximately one and three quarters (1¾) inch, however,alternate angles, lengths, and/or other dimensions may be substituted toaccommodate, for example, varying sizes of forms.

Plate 13685 is coupled to structural member 302 via sliding baseaperture 13698 of plate 13685 over a seven-eighths (⅞) inch threadedshear stud welded to the structural member 302. A nut is then threadedover the stud until it contacts the upwardly facing surface of the baseof plate 13685 in order to secure the plate to the structural member302.

It should be noted that although FIG. 13D depicts a single plate 13685with a first angle A₁, it is envisioned that multiple plates could bestacked and each plate could have varying dimensions and/or angles toallow each of the plates to be coupled to respective tie back rods orthe like similar to the stacked plates shown in FIG. 10B, as discussedabove, but having the features of fastener 13653.

Referring now to FIG. 13E, depicted is an alternate primary support13853, which includes a primary fastener 13884, plate 13885, secondaryfastener 13887, and plate base fastener 13886. As shown in FIG. 13D, thesecond end of each primary support 13853 is coupled to a respectiveprimary fastener 13884 and secondary fastener 13887. In the depictedembodiment, primary fastener 13884 and secondary fastener 13887 areseven-eighths inch (⅞″) diameter by two and one half inches (2½″) longcoupler nuts which are welded to plate 13885. The primary fastener 13684has a threaded aperture 13888 for engaging the threaded end of a primarytie back rod 13282, and the secondary fastener 13887 has a threadedaperture 13889 for engaging the threaded end of a secondary tie back rod13252. Although fasteners 13884 and 13887 are in the form of weldedcoupler nuts, alternate fasteners may be substituted.

The tie back rod 13282/primary fastener 13884 and the tie back rod13252/secondary fastener 13887 connect to existing structural member 302by means of a rectangular, bent plate 13885 with a length ofapproximately thirteen (13) inches, a width ranging from three inches(3″) to four and three quarters inches (4¾″), and a thickness of one (1)inch. However, the dimensions of plate 13885 may vary depending upon,for example, the governmental standard being met (e.g., OSHA 4:1 Failure(ULT), AASHTO ASD and 2:1 (ULT), AISC ASD AND 2:1 (ULT)). The plate13685 is made of a rigid material such as Grade 50 steel and the likeand has base aperture 13898. In the depicted embodiment, the body 13800of plate 13885 is bent at two angles A1 and A2. Angle A₁ isapproximately forty-five (45) degrees relative to the longitudinal axisof base 13802 of plate 13885, and angle A₂ is approximately twenty-five(25) degrees relative to the longitudinal axis of body 13800 of plate13885. As depicted in FIG. 13E, primary fastener 13884 is welded to theupwardly facing surface 13890 of the body 13800 and secondary fastener13887 is welded to the downwardly facing surface 13891 of the distal endof plate 13885. However, alternate angles, lengths, and/or otherdimensions may be substituted to accommodate, for example, varying sizesof forms.

Plate 13885 is coupled to structural member 302 via sliding baseaperture 13898 of plate 13885 over a seven-eighths (⅞) inch threadedshear stud welded to the structural member 302. A nut is then threadedover the stud until it contacts the upwardly facing surface of the baseof plate 13885 in order to secure the plate to the structural member13302.

Further, alternate attachment mechanisms 13060 may be substitutedwithout departing from the scope hereof. Or, alternate components of theattachment mechanism 13060 including, but not limited to, primarysupport 13253, secondary support 13254, primary tie system 13298, andsecondary tie system 13252 may be substituted without departing from thescope hereof.

Turning now to FIG. 13F, depicted is an alternate primary support 14253,which includes a primary fastener 14684, plate 14400, tie systemfastener 14406, and plate fastener 14402. This type of support may beused, for example, when a vertical support is available (e.g., rebar ora shear stud) to which the plate 14400 may be attached.

As shown in FIG. 13F, in the depicted embodiment, primary fastener 14684includes a tie system fastener 14406 that includes a bolt and nutcombination. Eyebolt 14408 includes a threaded aperture 14688 in a firstend for engaging the threaded end of the respective tie back rod 13282.Eyebolt 14408 is held to plate 14400 via tie system fastener 14406, thebolt of which passes through the head of the eyebolt 14408 andcorresponding apertures in the plate 14400. The bolt is held in placevia the tightening of the nut on the end of the bolt external to plate14400. However, tie back rod 13282 may be coupled to plate 14400 viaalternate fasteners without departing from the scope of the presentinvention.

Primary support 14253 connects to a vertical support 13286 coupled tothe structural member 302 by means of a cam-locking U-shaped bracket14400. That is, the U-shaped plate includes a bite bit cam 14402 thatbites into the vertical support 13286 when the plate and its associatedcam are rotated relative to vertical support to create a clamping forceon the vertical support. This clamping force prevents or minimizesmovement of plate 14253 relative to vertical support 13286.

In an alternative embodiment, primary support 14253 is rotated onehundred and eighty degrees prior to attachment to the vertical support.And, optionally, a sleeve 14410 may be included within plate 14400 tofurther prevent or minimize movement of plate 14253 relative to verticalsupport 13286. Alternate embodiments are also envisioned in which one ormore bolt and nut (and optionally washer) combinations are utilized tosqueeze the U shaped plate around the vertical support. In any of theabove described embodiments, embodiments are also envisioned in whichthe primary support 14253 is allowed to ride up (i.e., move vertically)the vertical support until a head or other interference limits movementthereof.

In embodiments of the present invention utilizing primary supports suchas primary support 14253, the primary support is typically coupled tothe vertical support prior to installation of the corresponding form.Next, the form, which has the tie rods pre-installed on it, is liftedinto place. Next, the tie rods are coupled to primary support 14253.Although other sequences can be substituted. For example, the primarysupport 14253 could be installed at the same time the form is liftedinto place and/or the tie rods could be installed after the form islifted into place.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention as defined by the appended claims.

1. We claim a form for creation of a structure, the form for supportinguncured concrete prior to curing comprising: a substantially verticalcomponent, said substantially vertical component having a substantiallyvertical inwardly facing surface and a substantially vertical outwardlyfacing surface; a substantially horizontal component having asubstantially horizontal inwardly facing surface and a substantiallyhorizontal outwardly facing surface, said substantially verticalcomponent located substantially perpendicular to said substantiallyhorizontal component and extending upwardly from said horizontalcomponent, the substantially vertical component and the substantiallyhorizontal component forming an L shape; at least one insert in orthrough at least one of the group consisting of the substantiallyvertical inwardly facing surface, the substantially horizontal inwardlyfacing surface; and combinations thereof; a rabbet extendinglongitudinally along the substantially horizontal component, the rabbetrecessed in said substantially horizontal outwardly facing surface atthe distal end thereof, the rabbet defined by top and side surfaces, theside surface being substantially vertical, and the top surface locatedat an angle of greater than ninety degrees relative to the side surface,the top surface tapered upwardly as it extends away from the sidesurface.
 2. A form according to claim 1, further comprising: at leastone form attachment configured for mating with the at least one insert.3. A form according to claim 2, wherein said at least one formattachment is an exterior reinforcement.
 4. A form according to claim 1,wherein said at least one insert is threaded.
 5. A form according toclaim 1, wherein said interconnection clip includes at least one railingsupport.
 6. A form according to claim 1, further comprising: at leastone of the group consisting of an interior reinforcement, an ornamentalfeature, and combinations thereof.
 7. A form according to claim 1,wherein a thickness of said substantially horizontal component and saidsubstantially vertical component is approximately two inches.
 8. A formaccording to claim 1, wherein an upwardly facing surface of saidsubstantially vertical component inclines upwardly and inwardly towardsaid form interior surface at an angle of approximately thirty degrees.9. A form according to claim 1, further comprising: a joining component.10. A form according to claim 9, wherein said joining component extendsat an angle of 45 degrees relative to said substantially verticalinwardly facing surface and said substantially horizontal inwardlyfacing surface.
 11. We claim a form for creation of a structure, theform for supporting uncured concrete prior to curing comprising: asubstantially vertical component, said substantially vertical componenthaving a substantially vertical inwardly facing surface and asubstantially vertical outwardly facing surface; a substantiallyhorizontal component having a substantially horizontal inwardly facingsurface and a substantially horizontal outwardly facing surface, saidsubstantially vertical component located substantially perpendicular tosaid substantially horizontal component and extending upwardly from saidhorizontal component, the substantially vertical component and thesubstantially horizontal component forming an L shape; at least oneinsert in or through at least one of the group consisting of thesubstantially vertical inwardly facing surface, the substantiallyhorizontal inwardly facing surface; and combinations thereof; and arabbet extending longitudinally along the substantially horizontalcomponent, the rabbet recessed in said substantially horizontaloutwardly facing surface at the distal end thereof; and a bevelextending longitudinally along the intersection of the substantiallyvertical outwardly facing surface and the substantially horizontaloutwardly facing surface.
 12. A form according to claim 11, wherein saidbevel is located at an angle of 45 degrees relative to saidsubstantially vertical outwardly facing surface and said substantiallyhorizontal outwardly facing surface.
 13. A form according to claim 1,wherein an upper corner of a distal end of said substantially horizontalcomponent is rounded.
 14. A form according to claim 1, furthercomprising: a protrusion extending longitudinally from saidsubstantially horizontal outwardly facing surface.
 15. A form accordingto claim 14, wherein the protrusion has a semicircular cross section.16. A form according to claim 14, wherein said protrusion is located atthe approximate midpoint of a proximal half of said substantiallyhorizontal component.
 17. A form according to claim 1, wherein saidrabbet is substantially L-shaped.
 19. A form according to claim 11,wherein an upper corner of a distal end of said substantially horizontalcomponent is rounded.
 20. A form according to claim 11, furthercomprising: a protrusion extending longitudinally from saidsubstantially horizontal outwardly facing surface.
 21. A form accordingto claim 20, wherein the protrusion has a semicircular cross section.22. A form according to claim 20, wherein said protrusion is located atthe approximate midpoint of a proximal half of said substantiallyhorizontal component.